FS-MTS-100.ALU USER MANUAL EN VERSION

Transcription

1 USER MANUAL EN VERSION

2 Company: FS Solutions B.V. Street, number: Octaanstraat 1D Address: 7463 PM Rijssen Country: The Netherlands Tel.: Fax.: This English version is the original version of this manual. Last modification: We reserve the right to make technical modifications diverging from the illustrations and information provided in this manual if such help to improve the machine or manual. The assembly instructions may only be duplicated for internal use. They must not be passed on to third parties. Adhering to the operating instructions is a prerequisite for fault-free operations and the fulfilment of any right to claim under warranty. Read the operating instructions before you start working with the unit. You must comply with the information contained in these operating instructions to ensure safe operation of the FS-MTS-100 conveyor system and to achieve the specified product characteristics and performance requirements. While every precaution has been taken in the preparation of this manual, the publisher assumes no responsibility for errors or omissions. Neither does FS Solutions assume liability for injury to persons or damage to equipment or property resulting from non-observance of these operating instructions. In such cases, any liability for defects is excluded FS Solutions B.V. 2

3 CONTENTS 1. GENERAL INFORMATION SAFETY NOTES GENERAL GENERAL SAFETY RISKS OVERHEAD INSTALLATION APPLIED SAFETY MEASURES PRECAUTIONS TRANSPORT AND STORAGE ASSEMBLY AND INSTALLATION COMPONENTS CONVEYOR SYSTEM ASSEMBLY INSTRUCTION MOUNTING THE MODULAR CHAIN DEMOUNTING THE DRUM DRIVE MAINTENENCE CLEANING THE CONVEYOR SPARE PARTS SPARE PARTS LIST

4 1. GENERAL INFORMATION 1.1 SYSTEM OVERVIEW For detailed dimensions of your conveyor system, please consult the attached drawing. Also you can request digital drawings from your system at FS Solutions at all times. 1. Sliding strip 2. Guide profile 3. Modular chain Drive section 5. Straight section 6. Idler section

5 2. SAFETY NOTES 2.1 GENERAL The conveyor, made of various machine components is a transportation system consisting of moving parts. Before starting up a conveyor system, it is imperative to ensure that the overall system containing components supplied by FS Solutions conforms to the provisions of the EC Machine Directive 2006/42/EC (29/06/2006) and the statutory provisions translated into national law. The following safety notes are primarily concerned with the use of FS-MTS-100 conveyor units, please also read safety instructions of the corresponding overall machine of which the FS-MTS-100 is a part of. CAUTION! Never work in any manner posing a safety hazard! 2.2 GENERAL SAFETY RISKS The conveyor system, assembled from machine components, is a machine with moving parts. Rotation of the modular belt presents potential mechanical hazards. All areas of the conveyor system presenting a hazard to persons must be secured by means of suitable guards. Applicable international standards as well as national regulations on safety and accident prevention must be met. Potential hazard zones must be separated off by guards and made inaccessible to persons. Protective fences can be installed around the system or protective enclosures can be fitted directly at the point of danger. If hazard zones cannot be separated off by guards, points of danger must be marked with warning signs. The main risks in the use of the conveyor are as follows The small gab between profile and the chain presents a risk of getting drawn in and crushed. Conveyor chains with catch plates, grippers, accumulating rollers or catch rollers, as well as chains fitted with clientspecific components: - Risk of being pulled in and crushing hazard in the area of drive and idler units, as well as small-radius horizontal curves. - Crushing hazard between railing and chain in the upper run. - Crushing hazard between leg joint and chain returning in the lower run. - When using these chain types, drive and idler units must be made inaccessible to operating personnel by means of guards (e.g. protective covers). The lower run must be screened off by guards (e.g. protective grilles or protection plate) at places where manual work is carried out directly on the conveyor system. Line transitions (if fitted): Risk of being pulled in and crushing hazard at transition to downstream line. Conveyor chains with catch plates, accumulating rollers and catch rollers: When using these chain types, drive and idler units must be made inaccessible to operating personnel by means of guards (e.g. protective covers). The lower run must be screened off by guards (e.g. protective grilles or protection plate) at places where manual work is carried out directly on the conveyor system. 5

6 2.3 OVERHEAD INSTALLATION If conveyors are installed above a headroom height of approximately 1.6m (overhead installation), the danger zone below the conveyor must be marked and, if necessary, segregated by means of suitable guards. Loads could fall from the conveyor. If traffic routes cross the danger zone, safe passages must be created on site by the owner. While an overhead conveyor is in operation, keep obstacles out of the area below the conveyor so as to avoid collisions. CAUTION! While in service, persons must keep out of the unprotected hazard zone below the conveyor. Safety helmets must be worn by operating, service and cleaning personnel entering the danger zone for servicing, repair, cleaning and operational work. 2.4 APPLIED SAFETY MEASURES The conveyor is standard equipped with a upstanding edge on the topside of the profile which locks the modular chain with a clearance of approximately 1mm on both sides of the chain. On the one hand they provide for guiding the conveyor modular chain, on the other, they prevent you from getting your hands or fingers between the modular chain and the profiles. Clearances between moving and static parts were decreased to a minimum where possible to minimize the chance of getting caught between them. The chains used for FS-MTS-100 tracks have been carefully selected and although they are modular and have a smooth surface without any large clearances to prevent getting caught in the chain. The emergency stop function is (if not specifically requested otherwise) located at an easy reachable position. The most common position is on one of the Legs. If the FS-MTS-100 conveyor is to be build into another machine, the supplier of the overall machine has the obligation of ensuring emergency stop functions over the overall system in which this conveyor is a part of, this emergency stop system has to be conform currently applicable machine guideline and national regulations and standards. 2.5 PRECAUTIONS The user/operator of the conveyor, has to take the following safety precautions This manual, in particular the safety instructions are read. Pay extra attention on the text written at the warning signs in this manual. Only to use the conveyor properly as it is intended. (see 1.1). This manual should always be available at the location where the conveyor is used. Operation, service and maintenance of the conveyor should be done by qualified and authorized personnel only. While operating the conveyor, watch out for other people near the conveyor. Before doing maintenance or repairs, make sure you have the power cable unplugged. Perform all operations controlled, thoughtfully and slowly. Don t put your hands and/or fingers on or near the conveyor when it s running. Any identified defects with the potential to impair safe operation are reported to the owner for the owner to take care of rectifying them. The system s power switch is switched off and protected from being switched back on again without authorisation before conducting cleaning, service or maintenance related duties. The owner must ensure that The system is only used for its intended purpose (see section 2 for details). The system is only operated if it is in proper working order and, in particular, that the safety devices are regularly inspected for effective operation. Requisite personal protective equipment is provided for and used by operating, servicing and repair personnel. The assembly instructions are kept in a legible state and are available in full at the place of machine use. The system is only operated, serviced and repaired by adequately qualified and authorised personnel. These persons receive regular instruction on all matters concerning work safety and environmental protection and are familiar with the assembly instructions and, in particular, with the safety warnings they contain. The system s main switch is switched off and protected from being switched back on again without authorisation before conducting servicing, repair and cleaning work. 6

7 3. TRANSPORT AND STORAGE During loading and/or transportation, please note that; The chain does not get stuck It is protected from the elements The conveyor system isn t pushed or pulled, because the rubber feet aren t designed for sliding It s free from excessive vibration Low air humidity Low dust accumulation When lifting the modular chains, keep the centre point of gravity in mind. Careless transport may result in damage that could interfere with the operation of the conveyor system. Make sure the conveyor system is installed or stored in a clean and dry environment. The best operating temperature is room temperature (ca 20 C), the permissible temperature is in range between -15 C and +75 C. CAUTION! Always unplug the power cable and lay the cable and plug on the conveyor when you move it. 7

8 4. ASSEMBLY AND INSTALLATION The conveyor is pre assembled and cut in assemble ready pieces at FS Solutions. The assembly of the conveyor system in the workspace is simple. Nevertheless, all assembly and installation work must be performed by qualified personnel. A detailed assembly instruction with pictures is added at 4.2. Assembly steps Place the conveyor, or assemble the separate components to one conveyor system. The conveyor system can be heightened by the adjustable feet using a wrench. Connect the conveyor electrically, and make sure that it is running in the right direction. Connect any in- and output systems or machines. CAUTION! Risk of electric shock! The conveyor may only apply the electric mains, after all assembly and installation tasks have ended. Ensure that the cables are away from walking paths. 4.1 COMPONENTS Circulation Profile Distance profile Drive Adjustable feet Note: A more detailed parts list has been added under chapter 8 Spare parts. 8

9 4.2 ASSEMBLY INSTRUCTIONS When delivered, the conveyor system is cut in pre assembled pieces and is easy to assemble. The following information funs for various widths of our FS-MTS-100 system. The drive, circulation, profiles and legs are pre- assembled. The parts only need to be connected together. Below are pictures of the procedure along with an explanation. Be sure all bolts and nuts are fastened firmly by hand. This because it will minimize the vibrations and with that, produced noise Connecting profiles Aligned slots in the profile are to be used for connecting profiles. A connecting plate is mounted in one end of a profile and connected by a T-slot block which in mounted in the slot of a profile. Then the other side of the connecting plate is slid into another profile in the same manner (clicking the T-slot block into the profile). Note here that the edges of the profile can be sharp (picture ) Connecting the circulation When mounting a circulation the connecting plate(s) is already fixed in the circulation. The other side of the connecting plate is assembled the same way a profile is connected to another profile (see 4.2.1) Connecting the drive When mounting the drive the connecting plate(s) is already fixed in the drive. The other side of the connecting plate is assembled the same way as a profile is connected to another profile (see 4.2.1). CAUTION: Connecting a drive to the local power network should always be executed by electrical qualified personnel. * T-slot blocks 9

10 4.2.4 Mounting the sliding strips The sliding strips are fitted on all four horizontal endings of the profile and serve to prevent wear and reduce noise. If not pre-drilled you can drill holes with the supplied drilling tool (picture 5) and connect the sliding strips to the profile with the supplied inserts. Drilling jigs are always on stock at FS Solutions and can be ordered if not supplied Alignment of the sprockets and modular belt It s very important that the modular chain belt is mounted in the correct direction. The arrows on the modular belt should point in the same direction as the running direction and be on the inside of the rotation facing the drive. For aligning the sprockets the teeth should lock in the pulling notch of the modular chain. In a two sprocket system this means you have to lock the teeth of the sprocket 2 notches from the centre. CAUTION! The arrows on the modular chain and in the schematic picture 5 are parallel and thus opposite direction to the mechanical rotation direction Securing the modular chain Once you have pulled the chain all the way through the profile you ll need an overlap of chain of approx 1 link. Make sure you have a bit of clearance left in the chains so you can lock them together. For more detailed pictures of mounting the chain see the next page (page ) Mounting the legs The legs are attached to the profile by 4 T-slot blocks and 4 bolts. After mounting you can adjust the height of the feet at the bottom with a wrench. Two different types of legs are shown on in the picture, both are mounted with the same T-slot blocks. Holes are predrilled unless project related reasons force otherwise. Note: After completion of the final assembly, before putting the system into operation for the first time, all mechanical connections such as screws, pins or rivets should be checked and tightened if necessary. CAUTION! Commencement of operation is prohibited until the conformity of the entire system in which the conveyor is installed has been documented in accordance with the provisions of the EC Machinery Directive 06/42/EC and the national legal requirements. 10

11 4.3 MOUNTING THE MODULAR CHAIN 1. Pull the chain through the profiles like on the picture. 2. Properly align the sprockets in the openings. Ziehen Sie die Kette durch die Profile, wie im Bild Richtig steigen die Ritzel in die Öffnungen. 3. Tighten the belt with 1 link overlaps. 4. Connect the chain ends by opening the side links Ziehen Sie den Gurt mit 1 link Überschneidungen. with a screwdriver. Note that these are fragile. Verbinden Sie die Kettenenden durch Öffnen der Seite Links mit einem Schraubendreher. Beachten Sie, dass diese zerbrechlich sind. 5. Stick a supplied pin through the links and lock the 6. Your conveyor should look like this. end of the chain end again with a screw driver. Ihr Förderband sollte wie folgt aussehen. Kleben Sie einen mitgelieferten Stift durch die Links und verriegeln Ende der Kette Ende wieder mit einem Schraubendreher. 11

12 USER MANUAL 4.4 DEMOUNTING THE DRUM DRIVE 1. Demount the modular chain as explained in Your conveyor should look like this. Ihr Förderband sollte wie folgt aussehen. El transportador debe tener este aspecto. 4. Remove the cover cap from the side of the drive. Nehmen Sie die Abdeckkappe von der Seite des Mounting the modular chain. Demontieren modularen Kette wie in 4.3 erklärt. Desmontar el eje de la cadena modular, se explicó en Unbolt the cover cap from the side of the drive, by unfastening the two upper bolts on both sides. Riegeln Sie die Abdeckkappe von der Seite des Antriebs durch Lösen der beiden oberen Schrauben von beiden Seiten. Desatornille la tapa de la cubierta del lado de la unidad, aflojando los dos tornillos superiores en ambas caras. 5. Your conveyor should look like this. Ihr Förderband sollte wie folgt aussehen. El transportador debe tener este aspecto. Antriebs. Quitar la tapa de la cubierta desde el lado de la unidad. 6. Remove the drum drive by lifting the it out with a slight horizontal tilt. Entfernen Sie den Trommelantrieb durch Anheben der es mit einem leichten horizontale Neigung. Extraiga la unidad de tambor por la elevación a cabo con una leve inclinación horizontal 12

13 5. MAINTENANCE The conveyor should periodically be checked for proper running. Depending on the length of the conveyor and the weight of the product it is wise to maintain a minimum of 500 to a maximum of 1000 hours to perform maintenance. Maintenance of the conveyor is valuable because it allows the life of the conveyor to be extended and the potential of interference is significantly reduced. The followings needs to be performed during maintenance: The entire conveyor is to be cleaned. However, pay attention that you don t wet the electrical components. Only use cleaners with a ph between 5.0 and 8.0. Check the modular chain for damage. Check the conveyor for any rack. The conveyor modular chain gets, especially with heavy loads, over time somewhat stretched. If this is the case the chain is to be tightened by removing a shackle. (see 6.1). Check all moving parts properly. 5.1 CLEANING THE CONVEYOR Remove dust and other contaminations weekly over the entire profile and the top of the modular chain. You don t have to get the chain out in order to do this. The dust you ll remove is probably mainly carton box dust. Once every 2 years the conveyor system needs to be cleaned thoroughly. This means the chain has to be taken from the profile and be cleaned by hand. When you mount the chain back in make sure you have a dry modular chain and frame. A chain assembly instruction as been added to this 4.3 mounting the modular chain. Method of cleaning 1. Periodic high pressure hot water rinse or steam cleaning should prove satisfactory. Spray the chain in place on each conveyor, both on the carry and in the return sections. This is usually done with the conveyors running, but the chain can be stationary for easy access to the undersides of the chain in the carry and return ways. 2. Warm water and mild soap are commonly used to clean the conveyors. 3. Foaming agents or other chemical cleaners may be used if they are compatible with the conveyor materials. Note: Keep water, steam and chemicals away from electrical disconnects, motors, photo cells etc 4. In some cases, E.G. Pet bottle lines, cleaners or combination Cleaner/lubricants are applied continuously or intermittently. Several types of automatic application systems are available. 5. In extreme situations,. It may be necessary to periodically clean the chain with a bristle brush. Clean the chain in place on the conveyor, both on the carry and in the return sections. Note: The main objective is to clean the chain carrying surface and underside as well as the wear strip and tracks. Note: Inspect conveyors often. Remove broken or jammed containers or pieces of containers as soon as they are detected. Use c leaning solutions to clean away excessive spillage. Lubricating the conveyor chain The conveyor systems of FS Solutions can be operated without lubrication. This is made possible by the excellent material properties of the sliding strips. Changing motor oil Most of the time FS Solutions uses WA* housings from SEW, with this motor it is not necessary to refill oil. The oil added on construction has been added for a lifetime. If you have a different motor you should regularly check the oil level of the motor reductor(s) and if necessary fill with the appropriate lubricant. Change the oil every operating hours or every two years. In case the application runs on synthetic oil you ll only need to change the oil every operating hours or every four years. 13

14 6. SPARE PARTS Because of the strong construction and quality of the conveyor system it has a high reliability. The conveyor consists of parts from the aluminium profiles of FS Solutions. If necessary, parts of this system can be ordered at FS Solutions. All other components are manufactured or delivered on FS instructions, and are in detail in our Technical documentation. These parts can also be ordered at FS Solutions. All spare parts are mainly the sliding parts. If the spare parts are not at stock, we can build them or search with you for an alternative. 6.1 SPARE PARTS LIST The following spare parts have been standard equipped with the conveyor (amounts depending on conveyor length): Sliding strips Inserts Sprocket (sprocket type depending on your type of drive) * Inserts * Sliding strip * Sprocket The following parts are not standard equipped and can be ordered at FS Solutions: 14

15 THE BEST IN FLEXIBLE TRANSPORT SYSTEMS